Digital transformation with outdated control systems

and what happens if you ignore both challenges

The article has some challenges to some businesses’ way of thinking

Industrial digitalisation…

It’s the phrase that’s been circling manufacturing for years. But while many businesses are trying to make sense of Industry 4.0, a large number are still quietly running plants on outdated — and increasingly fragile — control systems.

In his recent article for Process Industry Informer, inControl’s Sales & Marketing Director Ian Clarke seeks to cut through the hype and asks a tough but essential question:

Can you digitalise your plant while it’s still running on obsolete control equipment?

As ever, the answer isn’t straightforward. Digital transformation is often framed as shiny new investment in smart tech, dashboards, and predictive analytics. But without a stable foundation — and that means up-to-date, supported control infrastructure — any digital project can find itself on shaky ground.

It’s not about choosing between upgrading or digitalising.

“I strongly believe the two are very closely linked” explains Ian. “Ignoring obsolescence doesn’t just increase the risk of failure — it holds you back from making the most of the data already flowing through your automation systems.

“Too often we see manufacturers trying to retrofit sensors or run pilots in silos, without a clear roadmap or understanding of where the real value lies. That leads to “pilot purgatory” — short-term projects that never scale, and ambitions that never quite land.”

What’s the alternative?

Start with the systems you already have. Understand what data is available, assess your risks around obsolescence, and use those upgrade projects as a launchpad for wider digital ambitions. That’s where the real productivity gains are hiding — and where costs, downtime, and energy use can be improved without huge disruption.

Sound familiar? If you’re not sure where to start, Ian’s full article is now available to download from the link opposite.

It’s a practical, honest look at the challenges and opportunities in front of manufacturers today — written by someone who’s had plenty of experience on both sides of the discussion.